Joining and Fabrication of Metal Matrix Composites by Friction Stir Welding/Processing

Herein, friction stir welding (FSW) of metal matrix composites (MMCs) with different combinations of the reinforcement and the metal matrix is highlighted with a brief introduction into recent efforts that have been used to fabricate MMCs by FSW. As a solid state joining technique, FSW consumes significantly lower energy than conventional fusion welding processes. In addition to properly selecting the process parameters, the mechanical properties of the FSW joints of MMCs are closely related with the refinement and homogeneous distribution of reinforcements in the stir zone. The fatigue and fracture properties of MMCs may be enhanced or aggravated by FSW, depending on the combination of the reinforcement and the metal matrix. For FSW of MMCs, the selection of the tool material can also be a critical issue; the presence of hard reinforcements may increase the rate of tool wear. Macro- and microstructural phenomena for MMCs during FSW depend on the material flow due to plasticization and the behavior of the reinforcements. Even though FSW are generally expected to induce a homogeneous distribution of reinforcements in the stir zone (SZ), it can be difficult to obtain a homogeneous distribution of reinforcements in the SZ depending on the combination of the reinforcement and the metal matrix. The existence of reinforcements naturally affects the microstructure of the joint and can even induce the formation of intermetallics/complex phases in the joint. This review provides a general understanding of the joining or in-situ fabrication of MMCs using solid-state friction stirring.